Harley Davidson 2007 Softail. Service manual - page 1

 

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Harley Davidson 2007 Softail. Service manual - page 1

 

 

2007

SOFTAIL

SERVICE

MANUAL

The information in this Service Manual applies to all 2007 Softail models.
MAINTENANCE 1

CHASSIS 2

ENGINE 3

FUEL SYSTEM 4

ELECTRIC STARTER 5 DRIVE 6

TRANSMISSION 7

ELECTRICAL 8
APPENDIX
INDEX 

 

FOREWORD GENERAL

This Service Manual has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the Harley-Davidson product and assist in the performance of basic maintenance and repair. Secondly, it will introduce to the professional Harley-Davidson Technician the latest field-tested and factory-approved major repair methods. We sincerely believe that this Service Manual will make your association with Harley-Davidson products more pleasant and profitable.

HOWTO USE YOUR SERVICE MANUAL
Information is arranged as follows:
• Section 1-Maintenance
• Section 2-Chassis
• Section 3-Engine
• Section 4-Fuel System
• Section 5-Electric Starter
• Section 6-Drive
• Section 7-Transmission
• Section 8-Electrical
• Appendix A-Tools
• Appendix B-Wiring
• Appendix С-Metric Conversions
• Appendix D-Glossary

Use the TABLE OF CONTENTS following this FOREWORD or the INDEX at the back of the book to find the desired subject.

Note that each manual section contains sequentially numbered topics. The numbering system allows quick cross references throughout the document.

For example, the sixth topic (BRAKES) in section one (MAINTENANCE) could be referred to as:

1.6 BRAKES

This cross reference directs the reader to section 1 (MAINTENANCE) and topic 6 (BRAKES).


PREPARATION FOR SERVICE




Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a)

Good preparation is very important for efficient service work. A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible, and will reduce the incidence of misplaced tools and parts. A motorcycle that is excessively dirty should be cleaned before work starts. Cleaning will occasionally uncover sources of trouble. Tools, instruments and any parts needed for the job should be gathered before work is started. Interrupting a job to locate tools or parts is a distraction and causes needless delay. See APPENDIX A-TOOLS for equipment required for special service work.

NOTE

• To avoid unnecessary disassembly, carefully read all relative service information before repair work is started.

• In figure legends, the number which follows the name of a part indicates the quantity necessary for one complete assembly

SERVICE BULLETINS
In addition to the information presented in this Service Manual, Harley-Davidson Motor Company will periodically issue Service Bulletins to Harley dealers. Service Bulletins cover interim engineering changes and supplementary information.

USE GENUINE REPLACEMENT PARTS
Awarning
When replacement parts are required, use only genuine Harley-Davidson parts or parts with equivalent characteristics (which include type, strength and material). Failure to do so may result in product malfunction. This could result in death or serious injury.

To ensure satisfactory and lasting repairs, carefully follow the Service Manual instructions and use only genuine Harley-Davidson replacement parts. Behind the emblem bearing the words GENUINE HARLEY-DAVIDSON stand more than 100 years of design, research, manufacturing, testing and inspecting experience. This is your assurance that the parts you are using will fit right, operate properly and last longer

 

 

WARNINGS AND CAUTIONS
Statements in this service manual preceded by the following words are of special significance.
Adanger
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
AwARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. (00119a)
Acaution
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. (00139a)
CAUTION
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage (00140a)
AwARNING
• Proper service and repair is important for the safe, reliable operation of all mechanical products. The service procedures recommended and described in this Service Manual are effective methods for performing service operations. Some of these service operations require the use of tools specially designed for the purpose. These special tools should be used when and as recommended. It is important to note that some warnings against the use of specific service methods, which could damage the motorcycle or render it unsafe, are stated in this Service Manual. However, please remember that these warnings are not all-inclusive. Inadequate safety precautions could result in death or serious injury.

• Since Harley-Davidson could not possibly know, evaluate or advise the service trade of all possible ways in which service might be performed, or of the possible hazardous consequences of each method, we have not undertaken any such broad evaluation. Accordingly, anyone who uses a service procedure or tool which is not recommended by Harley-David-son must first thoroughly satisfy himself that neither his nor the operator’s safety will be jeopardized as a result. This could result in death or serious injury.

• Wear eye protection when using hammers, arbor or hydraulic presses, gear pullers, spring compressors, slide hammers and similar tools. Be especially cautious when using pulling, pressing or compressing equipment. The forces involved can cause parts to fly outward with considerable force, possibly resulting in death or serious injury.

 

PRODUCT REFERENCES
WARNING
Follow the directions listed on all products. Carefully read all labels, warnings and cautions before use. Inadequate safety precautions could result in death or serious injury.

When reference is made in this Service Manual to a specific brand name product, tool or instrument, an equivalent product, tool or instrument may be substituted.

Kent-Moore Products

All tools mentioned in this manual with an “HD”, MJ" or “B" preface must be ordered through:

Kent-Moore

SPX Corporation

28635 Mound Road

Warren, Michigan USA 48092-3499

Sealing and Threadlocking Products LOCTITE PRODUCTS

Some procedures in this Service Manual call for the use of Loctite® products. If you have any questions regarding Loctite product usage or retailer/wholesaler locations, please contact Loctite Corp. at www.loctite.com.
CONTENTS
All photographs, illustrations and procedures may not necessarily depict the most current model or component, but are based on the latest production information available at the time of publication.

Since product improvement is our continual goal, Harley-Davidson reserves the right to change specifications, equipment or designs at any time without notice and without incurring obligation.
 

 

 

TABLE OF CONTENTS
Page No.

SECTION 1-MAINTENANCE
1.1 General..................................................................................1-1

Servicing a New Motorcycle..........................................................................1-1

Safe Operating Maintenance........................................................................1-1

Shop Practices....................................................................................................................1-1

Repair Notes..................................................................................................................1-1

Safety........................................................................................................................................1-1

Removing Parts........................................................................................................1-1

Cleaning................................................................................................................................1-2

Disassembly and Assembly....................................................................1-2

Repair and Replacement Procedures..............................................1-2

Hardware and Threaded Parts..........................................................1-2

Threadlocking Agents......................................................................................1-2

Wiring, Hoses and Lines..............................................................................1-2

Instruments and Gauges............................................................................1 -2

Bearings................................................................................................................................1-2

Bushings..............................................................................................................................1-2

Exhaust System Leakage..........................................................................1 -2

Gaskets..................................................................................................................................1 -3

Lip Type Seals............................................................................................................1-3

О-Rings (Preformed Packings)..........................................................1-3

Gears........................................................................................................................................1-3

Shafts...................................................................................................................1-3

Part Replacement..................................................................................................1-3

Cleaning........................................................................................................................................1-3

Part Protection............................................................................................................1-3

Cleaning Process....................................................................................................1-3

Rust or Corrosion Removal....................................................................1-3

Tool Safety................................................................................................................................1-3

Air Tools................................................................................................................................1-3

Wrenches............................................................................................................................1-3

Pliers/Cutters/Prybars......................................................................................1-4

Hammers............................................................................................................................1-4

Punches/Chisels......................................................................................................1-4

Screwdrivers..................................................................................................................1-4

Ratchets and Handles....................................................................................1 -4

Sockets..................................................................................................................................1 -4

Storage Units................................................................................................................1 -4

1.2 Fuel and Oil....................................................................1-5

Fuel......................................................................................................................................................1-5

Gasoline Blends................................................................................................................1-5

Engine Oil...........................................................................1-5

Winter Lubrication..........................................................................................................1 -5

1.3 Maintenance Schedule................................1 -6

First Scheduled Maintenance......................................................................1 -6

1.4 Engine Oil and Filter........................................1-11

Checking and Adding Oil....................................................................................1-11

Type of Oil........................................................................................................................1-11

Checking Oil Level................................................................................................1-11

Recommended Oil Grades (table)................................................1-11

Changing Oil and Filter..........................................................................................1-12

 

 

Page No.
1.5 Battery Maintenance......................................1-13

General..........................................................................................................................................1-13

Battery Electrolyte Antidotes (table)..........................................1-13

Disconnection and Removal..........................................................................1-14

Installation and Connection............................................................................1-14

Inspection..................................................................................................................................1-15

Storage..........................................................................................................................................1-15

1.6 Brakes......................................................................................1-16

Fluid Inspection................................................................................................................1-16

Rear Brake Pedal..........................................................................................................1-17

Pedal Height..................................................................................................................1-17

Pedal Lubrication....................................................................................................1-17

Pedal Pad..........................................................................................................................1-17

1.7 Bleeding Brakes....................................................1-18

General..........................................................................................................................................1-18

Procedure..................................................................................................................................1-18

1.8 Brake Pads and Discs..................................1-19

Inspection..................................................................................................................................1-19

Brake Pads......................................................................................................................1-19

Brake Disc Thickness...................................................................1-19

Brake Disc Lateral Runout and Warpage..........................1-19

Brake Pad Replacement....................................................................................1-20

Rear Brake Caliper..............................................................................................1-20

Front Brake Caliper: All But FLSTSC......................................1 -22

1.9 Tires and Wheels..................................................1-23

Tires..................................................................................................................................................1 -23

Tire Pressures (table)......................................................................................1-23

Tire Replacement..........................................................................................................1 -24

Wheel Bearings................................................................................................................1-24

Wheel Spokes....................................................................................................................1 -24

1.10 Primary Chain........................................................1-25

General..........................................................................................................................................1-25

1.11 Primary Chaincase Lubricant... 1-26

Changing Lubricant....................................................................................................1 -26

1.12 Clutch..................................................................................1-28

Adjustment..............................................................................................................................1-28

1.13 Transmission Lubricant........................1-30

Changing Lubricant....................................................................................................1 -30

1.14 Rear Belt Deflection....................................1-31

Inspection..................................................................................................................................1-31

Rear Belt Deflection (Table)..................................................................1-31

Adjustment..............................................................................................................................1-32

1.15 Rear Belt and Sprockets......................1 -33

General..........................................................................................................................................1-33

Cleaning......................................................................................................................................1-33

Inspection..................................................................................................................................1-33

Sprockets..........................................................................................................................1-33

Rear Belt............................................................................................................................1-33

Drive Belt Wear Analysis (table)......................................................1 -34

1.16 Suspension Adjustments..................1-35

Rear Shock Preload..................................................................................................1-35
 

 

1.17 Steering Head Bearings: All But
FLSTSC..............................................................................................1-36

Adjustment................................................................................................................................1-36

Bearing Adjustment (Fall-away)........................................................1-36

Lubrication..................................................................................................................................1-36

1.18 Steering Head Bearings:

FLSTSC..............................................................................................1-37

General..........................................................................................................................................1 -37

Lubrication..........................................................................................................................1-37

Adjustment........................................................................................................................1-37

Adjustment................................................................................................................................1-38

1.19 Rocker Bearings: FLSTSC................1-39

Inspection....................................................................................................................................1-39

1.20 Front Fork Oil..........................................................1 -41

Replacing Fork Oil..........................................................................................................1 -41

1.21 Spark Plugs................................................................1-43

Inspection....................................................................................................................................1-43

1.22 Air Cleaner Filter................................................1 -44

Removal........................................................................................................................................1 -44

Installation..................................................................................................................................1-45

1.23 Cable and Chassis Lubrication 1-46

General..........................................................................................................................................1 -46

Cables and Hand Levers......................................................................................1 -46

Jiffy Stand..................................................................................................................................1 -46

1.24 Throttle Cables....................................................1 -47

Cable Inspection, Lubrication and Adjustment....................1-47

Inspection and Lubrication........................................................................1-47

Adjustment........................................................................................................................1 -48

1.25 Engine Mounts......................................................1-49

Inspection....................................................................................................................................1-49

1.26 Headlamp Alignment..................................1-50

Inspection....................................................................................................................................1-50

Adjustment................................................................................................................................1-51

FLSTSC Models........................................................................................................1-51

FLSTC/FLSTF/FLSTN/FXST/FXSTB/FXSTC Models 1-51 FXSTD Models............................................................................................................1-51

1.27 Critical Fasteners............................................1-52

Inspection....................................................................................................................................1-52

Critical Fasteners (table)..............................................................................1 -52

1.28 Storage..............................................................................1-53

General..........................................................................................................................................1 -53

Removal From Storage..........................................................................................1 -54


1.29 Troubleshooting......................... 1-55

General..........................................................................................................................................1-55

Engine..............................................................................................................................................1-55

Starter Motor Does Not Operate or Does Not

Turn Engine Over..................................................................................................1-55

Engine Turns Over But Does Not Start..................................1-55

Starts Hard........................................................................................................................1-55

Starts But Runs Irregularly or Misses......................................1-55

A Spark Plug Fouls Repeatedly........................................................1-56

Pre-Ignition or Detonation (Knocks or Pings)..............1 -56

Overheating....................................................................................................................1-56

Valve Train Noise..................................................................................................1-56

Excessive Vibration............................................................................................1-56

Check Engine Light Illuminates During Operation 1-56

Lubrication System......................................................................................................1 -56

Oil Does Not Return To Oil Tank....................................................1-56

Engine Uses Too Much Oil Or Smokes Excessively 1-56 Engine Leaks Oil From Cases, Push Rods, Hoses 1-56

Low Oil Pressure....................................................................................................1 -57

High Oil Pressure....................................................................................................1-57

Electrical System............................................................................................................1-57

Alternator Does Not Charge..................................................................1 -57

Alternator Charge Rate Is Below Normal............................1-57

Speedometer Operates Erratically................................................1 -57

Transmission........................................................................................................................1-57

Shifts Hard...........................................................................1-57

Jumps Out Of Gear..............................................................................................1 -57

Clutch Slips......................................................................................................................1-57

Clutch Drags Or Does Not Release............................................1-57

Clutch Chatters..........................................................................................................1 -57

Handling........................................................................................................................................1-58

Irregularities....................................................................................................................1-58

Brakes..............................................................................................................................................1-58

Brake Does Not Hold Normally..........................................................1-58

SECTION 2-CHASSIS
2.1 Specifications..............................................................2-1

Tires....................................................................................................................................................2-2

Tire Fitment, Tubeless Cast Wheels (table)..................2-2

Tire Fitment, Laced Wheels (table)..............................................2-2

Tire Pressure, All Models (table)....................................................2-3

2.2 Torque Values..............................................................2-4

2.3 Vehicle Identification

Number (V.I.N.)......................................................................2-7

General..........................................................................................................................................2-7

2.4 Front Wheel: All But

FLSTSC/FXSTD......................................................................2-9

Removal........................................................................................................................................2-9

Disassembly..........................................................................................................................2-9

Disc Wheel........................................................................................................................2-9

Laced Wheel..................................................................................................................2-9

Cleaning and Inspection......................................................................................2-11

Assembly....................................................................................................................................2-11

Disc Wheel........................................................................................................................2-11

Laced Wheel..................................................................................................................2-11

Installation..................................................................................................................................2-11
 

 

2.5 Front Wheel: FXSTD........................................2-12

Removal........................................................................................................................................2-12

Disassembly..........................................................................................................................2-12

Cleaning and Inspection......................................................................................2-12

Assembly....................................................................................................................................2-13

Installation..................................................................................................................................2-13

2.6 Front Wheel: FLSTSC....................................2-14

Removal........................................................................................................................................2-14

Disassembly..........................................................................................................................2-14

Cleaning and Inspection......................................................................................2-14

Assembly....................................................................................................................................2-14

Installation..................................................................................................................................2-16

2.7 Rear Wheel......................................................................2-17

Removal........................................................................................................................................2-17

Disassembly..........................................................................................................................2-17

Cleaning and Inspection......................................................................................2-19

Assembly....................................................................................................................................2-19

Installation..................................................................................................................................2-19

2.8 Sealed Wheel Bearings..............................2-20

Inspection..................................................................................................................................2-20

Removal........................................................................................................................................2-20

Installation..................................................................................................................................2-21

2.9 Wheel Lacing: 16 In. Rim..........................2-22

General..........................................................................................................................................2-22

Procedure..................................................................................................................................2-23

2.10 Wheel Lacing: 21 In. Rim......................2-25

Procedure..................................................................................................................................2-25

2.11 Truing Laced Wheel......................................2-28

General..........................................................................................................................................2-28

Lateral Truing........................................................................................................................2-28

Wheel Offset Dimensions (table)....................................................2-29

Radial Truing........................................................................................................................2-31

2.12 Disc Rim Runout................................................2-32

General..........................................................................................................................................2-32

Lateral Runout....................................................................................................................2-32

Radial Runout......................................................................................................................2-32

2.13 Tires........................................................................................2-33

General..........................................................................................................................................2-33

Removal........................................................................................................................................2-34

Cleaning, Inspection and Repair..............................................................2-34

Installation..................................................................................................................................2-35

Tube Type Tires........................................................................................................2-35

T ubeless Tires............................................................................................................2-35

2.14 Vehicle Alignment............................................2-36

Inspection..................................................................................................................................2-36

2.15 Front Brake Master Cylinder..........2-37

General..........................................................................................................................................2-37

Removal/Disassembly............................................................................................2-37

Cleaning and Inspection......................................................................................2-38

Assembly/Installation................................................................................................2-40
2.16 Rear Brake Master

Cylinder/Reservoir..........................................................2-42

Removal......................................................................................................................................2-42

Installation................................................................................................................................2-42

Disassembly..........................................................................................................................2-45

Cleaning and Inspection......................................................................................2-46

Assembly....................................................................................................................................2-46

2.17 Front Brake Caliper:

All But FLSTSC....................................................................2-48

Removal......................................................................................................................................2-48

Disassembly..........................................................................................................................2-48

Cleaning, Inspection and Repair............................................................2-51

Assembly....................................................................................................................................2-52

Installation................................................................................................................................2-53

2.18 Front Brake Caliper: FLSTSC... 2-54

Front Brake Caliper....................................................................................................2-54

Removal..............................................................................................................................2-54

Disassembly..........................................................................................................................2-54

Cleaning and Inspection......................................................................................2-55

Assembly....................................................................................................................................2-56

Installation........................................................................................................................2-56

Brake Reaction Link..................................................................................................2-58

Removal..............................................................................................................................2-58

Installation........................................................................................................................2-58

2.19 Rear Brake Caliper: All But

FXST/FXSTB/FXSTC/FLSTF............................2-60

Removal......................................................................................................................................2-60

Disassembly..........................................................................................................................2-60

Cleaning, Inspection and Repair............................................................2-63

Assembly....................................................................................................................................2-63

Installation................................................................................................................................2-64

2.20 Rear Brake Caliper:

FXST/FXSTB/FXSTC/FLSTF............................2-65

Removal......................................................................................................................................2-65

Disassembly..........................................................................................................................2-65

Cleaning, Inspection and Repair............................................................2-68

Assembly....................................................................................................................................2-69

Installation................................................................................................................................2-70

2.21 Front Forks: All But FLSTSC.... 2-71

General..........................................................................................................................................2-71

Removal......................................................................................................................................2-71

Disassembly..........................................................................................................................2-71

Cleaning and Inspection......................................................................................2-71

Assembly....................................................................................................................................2-75

Installation................................................................................................................................2-75
 

 

2.22 Springer Fork: FLSTSC..........................2-76

General..........................................................................................................................................2-76

Handlebar and Risers..............................................................................................2-76

Removal................................................................................................................................2-76

Installation..........................................................................................................................2-76

Front Shock Absorber..............................................................................................2-78

Removal................................................................................................................................2-78

Installation..........................................................................................................................2-78

Rigid Fork....................................................................................................................................2-79

Removal................................................................................................................................2-79

Installation..........................................................................................................................2-79

Spring Fork................................................................................................................................2-80

Disassembly....................................................................................................................2-80

Assembly..............................................................................................................................2-82

Fork Rockers..........................................................................................................................2-84

Removal................................................................................................................................2-84

Installation..........................................................................................................................2-84

Fork Stem Bearings....................................................................................................2-85

Removal/Installation............................................................................................2-85

2.23 Steering Head........................................................2-86

Removal........................................................................................................................................2-86

FLSTC, FLSTF, FLSTN Models........................................................2-86

FXSTD, FXST, FXSTC, FXSTB Models..............................2-86

FLSTSC Models........................................................................................................2-87

Cleaning and Inspection......................................................................................2-87

All Models............................................................................................................................2-87

Disassembly............................................................................................................................2-87

Removing Lower Bearings From Fork Stem..................2-87

Steering Head Bearing Race Removal..................................2-88

Assembly......................................................................................................................................2-88

Installation..................................................................................................................................2-89

FLSTC, FLSTF, FLSTN Models........................................................2-89

FXSTD, FXST, FXSTC, FXSTB Models..............................2-89

FLSTSC Models........................................................................................................2-89

2.24 Rear Fork........................................................................2-90

Removal........................................................................................................................................2-90

Cleaning and Inspection......................................................................................2-90

Installation..................................................................................................................................2-91

2.25 Rear Shock Absorbers............................2-92

General..........................................................................................................................................2-92

Removal........................................................................................................................................2-92

Installation..................................................................................................................................2-92

2.26 Throttle Control....................................................2-93

Removal/Disassembly..............................................................................................2-93

Cleaning and Inspection......................................................................................2-93

Assembly/Installation................................................................................................2-93

Cable Routing......................................................................................................................2-94

All Models Except FLSTSC/FXSTD............................................2-94

FLSTSC Models........................................................................................................2-94

FXSTD Models............................................................................................................2-94

2.27 Handlebars: All but

FLSTF/FLSTSC......................................................................2-95

Removal........................................................................................................................................2-95

FXSTD....................................................................................................................................2-96

Installation..................................................................................................................................2-97

FXSTD....................................................................................................................................2-97
2.28 Handlebars: FLSTF.................... 2-99

Removal........................................................................................................................................2-99

Installation..................................................................................................................................2-100

FXSTD....................................................................................................................................2-102

2.29 Clutch Hand Control.................. 2-102

Removal........................................................................................................................................2-102

Installation..................................................................................................................................2-102

2.30 Front Fender: All But FLSTSC .. 2-103

FXST, FXSTB, FXSTC Models....................................................................2-103

Removal................................................................................................................................2-103

Installation..........................................................................................................................2-103

FLSTC, FLSTN Models........................................................................................2-103

Removal................................................................................................................................2-103

Installation..........................................................................................................................2-103

FLSTF Models.................................................................................................................2-104

Removal................................................................................................................................2-104

Installation..........................................................................................................................2-104

FXSTD Models..................................................................................................................2-104

Removal................................................................................................................................2-104

Installation....................................................................2-104

2.31 Front Fender: FLSTSC............... 2-105

Removal........................................................................................................................................2-105

Front Fender..................................................................................................................2-105

Front Fender Bearing Replacement.........................2-105

Installation..................................................................................................................................2-106

2.32 Rear Fender: FLSTC................... 2-107

Removal........................................................................................................................................2-107

Installation..................................................................................................................................2-108

2.33 Rear Fender: FLSTF................... 2-109

Removal........................................................................................................................................2-109

Installation..................................................................................................................................2-110

2.34 Rear Fender:

FXST/FXSTB/FXSTC........................... 2-111

Removal........................................................................................................................................2-111

Installation..................................................................................................................................2-112

2.35 Rear Fender: FXSTD.................. 2-113

Removal........................................................................................................................................2-113

Disassembly..........................................................................................................................2-113

Assembly....................................................................................................................................2-114

Installation..................................................................................................................................2-114

2.36 Rear Fender: FLSTSC................ 2-115

Removal........................................................................................................................................2-115

Disassembly..........................................................................................................................2-115

Assembly....................................................................................................................................2-116

Installation..................................................................................................................................2-116

2.37 Rear Fender: FLSTN................... 2-117

Removal........................................................................................................................................2-117

Disassembly..........................................................................................................................2-117

Assembly....................................................................................................................................2-119

Installation..................................................................................................................................2-119

2.38 Rear Fender Wire Conduit:

All But FXSTD..................................... 2-120

Installation..................................................................................................................................2-120
 

 

 2.39 Belt Guard/Debris Deflector...... 2-122

Removal........................................................................................................................................2-122

Belt Guard..........................................................................................................................2-122

Debris Deflector........................................................................................................2-122

Installation..................................................................................................................................2-122

Belt Guard..........................................................................................................................2-122

Debris Deflector........................................................................................................2-122

2.40 Jiffy Stand................................... 2-123

Cleaning........................................................................................................................................2-123

Removal........................................................................................................................................2-124

Installation..................................................................................................................................2-124

2.41 Fork Lock.................................... 2-125

Removal........................................................................................................................................2-125

Installation..................................................................................................................................2-125

2.42 Seat/Strap Retention Nut........... 2-126

Replacement..........................................................................................................................2-126

2.43 Seat: FXST/FXSTB..................... 2-127

Removal/Installation..................................................................................................2-127

Seat Strap..........................................................................................................................2-127

Seat............................................................................................................................................2-127

2.44 Seat: FXSTC............................... 2-128

Removal/Installation..................................................................................................2-128

Seat Strap..........................................................................................................................2-128

Seat............................................................................................................................................2-128

2.45 Seat: FXSTD............................... 2-129

Removal/Installation..................................................................................................2-129

2.46 Seat: FLSTSC/FLSTN/

FLSTF/FLSTC..................................... 2-130

Removal/Installation..................................................................................................2-130

2.47 Luggage Rack: FLSTN............... 2-131

Removal/Installation..................................................................................................2-131

2.48 Saddlebags: FLSTC................... 2-132

Removal........................................................................................................................................2-132

Installation..................................................................................................................................2-132

2.49 Windshield: FLSTC.................... 2-133

Removal........................................................................................................................................2-133

Installation..................................................................................................................................2-133
SECTION 3-ENGINE
3.1 Specifications............................................................3-1

3.2 Engine Torque Values (table)..........3-3

3.3 Service Wear Limits..........................................3-4

General..........................................................................................................................................3-4

3.4 Engine Oil Flow........................................................3-6

Oil Feed........................................................................................................................................3-6

Top End........................................................................................................................................3-7

Bottom End..............................................................................................................................3-7

Chain Guide Bracket..................................................................................................3-11

Oil Return....................................................................................................................................3-11
3.5 Oil Pump Operation..........................................3-12

General..........................................................................................................................................3-12

Operation....................................................................................................................................3-12

3.6 Breather Operation............................................3-13

General..........................................................................................................................................3-13

3.7 Oil Pressure..................................................................3-14

Oil Pressure Indicator Lamp..........................................................................3-14

Checking Oil Pressure............................................................................................3-14

3.8 How To Use This Section........................3-15

Top End Repair................................................................................................................3-15

Bottom End Repair......................................................................................................3-15

Typical Symptoms........................................................................................................3-15

3.9 Top End Service....................................................3-16

Engine In Chassis........................................................................................................3-16

Engine Removed From Chassis..............................................................3-17

3.10 Bottom End Service....................................3-18

Engine In Chassis: Cam Compartment Service..............3-18

Engine Removed: Flywheel Compartment

Service or Complete Engine Overhaul..........................................3-19

3.11 Troubleshooting................................................3-20

Diagnosing Valve Train Noise....................................................................3-20

Compression Test........................................................................................................3-20

Compression Test Results (table)................................................3-20

Cylinder Leakage Test..........................................................................................3-21

Diagnosing Smoking Engine or High Oil Consumption 3-21

Check Prior To Cylinder Head Removal............................3-21

Check After Cylinder Head Removal........................................3-21

3.12 Stripping Motorcycle For Service 3-22

Procedure..................................................................................................................................3-22

3.13 Assembling Motorcycle

After Service............................................................................3-23

Procedure..................................................................................................................................3-23

3.14 Removing Engine From Chassis 3-24

Procedure..................................................................................................................................3-24

3.15 Installing Engine In Chassis..........3-25

Procedure..................................................................................................................................3-25

3.16 Top End Overhaul: Disassembly 3-27

General..........................................................................................................................................3-27

Breather Assembly......................................................................................................3-27

Rocker Arm Support Plate................................................................................3-28

Push Rods, Lifters and Covers..................................................................3-29

Cylinder Head......................................................................................................................3-30

Cylinder........................................................................................................................................3-31

Piston..............................................................................................................................................3-33

3.17 Top End Overhaul: Assembly .. 3-34

General..........................................................................................................................................3-34

Piston..............................................................................................................................................3-34

Cylinder........................................................................................................................................3-35

Cylinder Head......................................................................................................................3-38

Push rods, Lifters and Covers....................................................................3-41

Rocker Arm Support Plate................................................................................3-42

Breather Assembly......................................................................................................3-43
 

 

 3.18 Bottom End Overhaul:

Disassembly..............................................................................3-45

General..........................................................................................................................................3-45

Cover and Cam Support Plate....................................................................3-45

Crankcase..................................................................................................................................3-49

Counterbalancer Assembly..............................................................................3-50

3.19 Bottom End Overhaul: Assembly 3-53

General..........................................................................................................................................3-53

Counterbalancer Assembly..............................................................................3-53

Balance Sprocket Spacers (table)..................................................3-54

Crankcase..................................................................................................................................3-56

Cover and Cam Support Plate....................................................................3-60

Rear Cam Sprocket Spacers (Table)........................................3-62

3.20 Breather Assembly........................................3-65

Removal Overview........................................................................................................3-65

Disassembly............................................................................................................................3-65

Cleaning and Inspection......................................................................................3-65

Assembly......................................................................................................................................3-65

Installation Overview..................................................................................................3-65

3.21 Rocker Arm Support Plate................3-66

Removal Overview........................................................................................................3-66

Disassembly............................................................................................................................3-66

Cleaning and Inspection......................................................................................3-66

Assembly......................................................................................................................................3-69

Installation Overview..................................................................................................3-69

3.22 Push Rods, Lifters and Covers 3-70

Removal Overview........................................................................................................3-70

Disassembly............................................................................................................................3-70

Cleaning and Inspection......................................................................................3-70

Lifter Inspection..................................................................................................................3-71

Assembly......................................................................................................................................3-72

Installation Overview..................................................................................................3-72

3.23 Cylinder Head........................................................3-73

Removal Overview........................................................................................................3-73

Disassembly............................................................................................................................3-73

Cleaning........................................................................................................................................3-75

Inspection....................................................................................................................................3-75

Cylinder Head..............................................................................................................3-75

Valve Guides..................................................................................................................3-76
Valve Stem To Guide Clearance Service

Wear Limits (table)................................................................................................3-76

Valves......................................................................................................................................3-76

Valve Springs................................................................................................................3-76

Tapered Keepers....................................................................................................3-76

Valve Seats......................................................................................................................3-76

Valve Guide Replacement................................................................................3-77

Removal...................................................................3-77

Installation..........................................................................................................................3-78

Valve Stem To Guide Clearance (table)..............................3-81

Valve and Seat Relacing....................................................................................3-82
Assembly......................................................................................................................................3-85

Installation Overview..................................................................................................3-87
 

3.24 Cylinder....................................... 3-88

Removal Overview........................................................................................................3-88

Cleaning........................................................................................................................................3-88

Inspection..................................................................................................................................3-89

Deglazing Cylinder........................................................................................................3-90

Boring and Honing Cylinder............................................................................3-92

Installation Overview..................................................................................................3-92

Oversize Pistons/Cylinder Bores (table)..............................3-92

3.25 Piston.......................................... 3-93

Removal Overview........................................................................................................3-93

Disassembly..........................................................................................................................3-93

Piston Rings....................................................................................................................3-93

Cleaning........................................................................................................................................3-93

Inspection..................................................................................................................................3-94

Assembly....................................................................................................................................3-96

Piston Rings....................................................................................................................3-96

Installation Overview..................................................................................................3-97

3.26 Cover and Cam Support Plate... 3-99

Removal Overview........................................................................................................3-99

Camshafts..................................................................................................................................3-100

Removal................................................................................................................................3-100

Assembly............................................................................................................................3-101

Oil Pressure Relief Valve....................................................................................3-103

Removal................................................................................................................................3-103

Installation..........................................................................................................................3-103

Cam Needle Bearings..............................................................................................3-104

Removal................................................................................................................................3-104

Installation..........................................................................................................................3-105

Cleaning and Inspection......................................................................................3-106

Oil Pressure Valve................................................................................................3-106

Cam Support Plate..............................................................................................3-106

Installation Overview..................................................................................................3-106

3.27 Oil Pump...................................... 3-107

Removal Overview........................................................................................................3-107

Cleaning and Inspection......................................................................................3-107

Installation and Overview....................................................................................3-108

3.28 Crankcase................................... 3-109

Removal Overview........................................................................................................3-109

Right Crankcase Half................................................................................................3-109

Chain Guide Screen..........................................................................................3-109

Crankshaft Bearing..............................................................................................3-109

Piston Jets........................................................................................................................3-110

Left Crankcase Half....................................................................................................3-111

Crankshaft (Roller) Bearing....................................................................3-111

Cylinder Studs....................................................................................................................3-113

Removal................................................................................................................................3-113

Installation..........................................................................................................................3-113

Pipe Plug and Oil Fittings..................................................................................3-113

Removal/Installation..........................................................................................3-113

Cleaning and Inspection......................................................................................3-114

Installation Overview..................................................................................................3-114
 

3.29 Counterbalancer Assembly...... 3-115

Removal Overview........................................................................................................3-115

Cleaning, Inspection and Repair..............................................................3-115

General..................................................................................................................................3-115

Balance Shaft Removal................................................................................3-115

Balance Shaft Installation..........................................................................3-116

Balance Shaft Support Bearings....................................................3-117

Front and Rear Balance Sprockets..............................................3-118

Hydraulic Tensioners........................................................................................3-118

Chain Tensioner Guides..............................................................................3-118

Chain Guide Bracket..........................................................................................3-118

Balance Chain............................................................................................................3-118

Installation Overview..................................................................................................3-118

3.30 Flywheel/Connecting Rod......... 3-119

Removal Overview........................................................................................................3-119

Inspection..................................................................................................................................3-119

Installation Overview..................................................................................................3-119

3.31 Oil Tank....................................... 3-120

Removal/Disassembly............................................................................................3-120

Oil Tank................................................................................................................................3-120

Oil Line Fittings/Retainers..........................................................................3-122

Installation..................................................................................................................................3-123

SECTION 4-FUEL SYSTEM
4.1 Specifications............................................................4-1

Torque Values (table)..............................................................................................4-1

4.2 Electronic Fuel Injection (EFI)

System................................................................................................4-3

General..........................................................................................................................................4-3

T roubleshooting................................................................................................................4-3

4.3 Idle Speed..........................................................................4-5

General..........................................................................................................................................4-5

4.4 Air Cleaner........................................................................4-6

Removal........................................................................................................................................4-6

Installation..................................................................................................................................4-6

Backplate Assembly: HDI Models..........................................................4-7

4.5 Fuel Tank............................................................................4-8

General..........................................................................................................................................4-8

Removal........................................................................................................................................4-8

Cleaning and Inspection......................................................................................4-12

Installation..................................................................................................................................4-12

All But FXSTDI............................................................................................................4-12

4.6 Throttle Position Sensor (TP)..........4-14

General..........................................................................................................................................4-14

Removal........................................................................................................................................4-14

Installation..................................................................................................................................4-14

4.7 Intake Air Temperature Sensor

(IAT)..........................................................................................................4-15

General..........................................................................................................................................4-15

Removal........................................................................................................................................4-15

Installation..................................................................................................................................4-15

 

 
4.8 Engine Temperature Sensor (ET) 4-16

General..........................................................................................................................................4-16

Removal......................................................................................................................................4-16

Installation................................................................................................................................4-17

4.9 Induction Module..................................................4-18

Removal......................................................................................................................................4-18

Installation................................................................................................................................4-20

4.10 Idle Air Control (IAC)..................................4-21

General..........................................................................................................................................4-21

Removal......................................................................................................................................4-21

Installation................................................................................................................................4-21

4.11 Manifold Absolute Pressure Sensor

(MAP)....................................................................................................4-22

General..........................................................................................................................................4-22

Removal......................................................................................................................................4-22

Installation................................................................................................................................4-22

4.12 Oxygen Sensor....................................................4-23

General..........................................................................................................................................4-23

Removal......................................................................................................................................4-23

Installation................................................................................................................................4-23

4.13 Fuel Injectors..........................................................4-25

General..........................................................................................................................................4-25

Removal......................................................................................................................................4-25

Installation................................................................................................................................4-26

4.14 Fuel Pump/Fuel Gauge

Sending Unit............................................................................4-27

General..........................................................................................................................................4-27

Removal......................................,........................................................4-27

Disassembly/Assembly........................................................................................4-30

Installation................................................................................................................................4-34

4.15 Fuel Pressure Test........................................4-35

General..........................................................................................................................................4-35

Testing..................................................................................................................................4-35

4.16 Exhaust System: FXST/FLSTC/

FXSTB/FXSTC........................................................................4-38

Mufflers..........................................................................................................................................4-38

Removal..............................................................................................................................4-38

Assembly............................................................................................................................4-38

System..........................................................................................................................................4-38

Removal..............................................................................................................................4-38

Installation........................................................................................................................4-39

4.17 Exhaust System: FXSTD/FLSTF 4-41

Mufflers..........................................................................................................................................4-41

Removal..............................................................................................................................4-41

Assembly............................................................................................................................4-41

System..........................................................................................................................................4-42

Removal..............................................................................................................................4-42

Installation........................................................................................................................4-42

4.18 Exhaust System: FLSTN......................4-44

Mufflers..........................................................................................................................................4-44

Removal..............................................................................................................................4-44

Assembly............................................................................................................................4-44

System..........................................................................................................................................4-45

Removal..............................................................................................................................4-45

Installation........................................................................................................................4-45

4.19 Exhaust System: FLSTSC..................4-47

Removal........................................................................................................................................4-47

Installation..................................................................................................................................4-48

4.20 Intake Leak Test..................................................4-50

General..........................................................................................................................................4-50

Leak Tester..............................................................................................................................4-50

Parts List..............................................................................................................................4-50

Tester Assembly......................................................................................................4-50

Tester Adjustment..................................................................................................4-50

Procedure....................................................................................................................................4-51

4.21 Evaporative Emissions Control: CA

Models................................................................................................4-52

General..........................................................................................................................................4-52

Charcoal Canister..........................................................................................................4-53

Removal................................................................................................................................4-53

Installation..........................................................................................................................4-53

Hose Routing/Replacement............................................................................4-54

SECTION 5-ELECTRIC STARTER

5.1 Specifications............................................................5-1

Torque Values......................................................................................................................5-1

5.2 Electric Starter System..............................5-2

General..........................................................................................................................................5-2

Starter Relay..................................................................................................................5-2

Operation....................................................................................................................................5-2

5.3 Starter Relay................................................................5-5

Removal........................................................................................................................................5-5

Installation..................................................................................................................................5-5

5.4 Starter......................................................................................5-6

Removal........................................................................................................................................5-6

Installation..................................................................................................................................5-6

Disassembly, Inspection and Repair..................................................5-7

Assembly......................................................................................................................................5-10

5.5 Starter Solenoid......................................................5-12

General..........................................................................................................................................5-12

Disassembly............................................................................................................................5-12

Assembly......................................................................................................................................5-12

SECTION 6-DRIVE

6.1 Specifications............................................................6-1

Torque Values (Table)............................................................................................6-1

6.2 Primary Chaincase............................................6-2

General..........................................................................................................................................6-2

Primary Chaincase Cover..................................................................................6-2

Removal................................................................................................................................6-2

Installation..........................................................................................................................6-3

Primary Chaincase Housing............................................................................6-4

Removal.............................................................................6-4

Inspection............................................................................................................................6-4

Installation..........................................................................................................................6-4

Mainshaft Bearing and Lip Seal................................................................6-6

Removal................................................................................................................................6-6

Shifter Shaft Bushing................................................................................................6-7
6.3 Drive Components..............................................6-8

Primary Chain and Compensating Sprocket..........................6-8

Removal................................................................................................................................6-8

Installation..........................................................................................................................6-10

6.4 Clutch........................................................................................6-14

Removal/Installation..................................................................................................6-14

Clutch Pack Only............................................................................................................6-14

Partial Disassembly............................................................................................6-14

Assembly............................................................................................................................6-14

Cleaning and Inspection..............................................................................6-16

Clutch Pack and Bearing....................................................................................6-17

Complete Disassembly..................................................................................6-17

Assembly............................................................................................................................6-18

6.5 Transmission Sprocket................ 6-20

Removal........................................................................................................................................6-20

Cleaning and Inspection......................................................................................6-21

Installation..................................................................................................................................6-21

6.6 Drive Belt....................................... 6-23

Removal........................................................................................................................................6-23

Inspection..................................................................................................................................6-23

Installation..................................................................................................................................6-24

SECTION 7-TRANSMISSION

7.1 Specifications..............................................................7-1

Torque Values....................................................................................................................7-2

7.2 Transmission................................................................7-3

General..........................................................................................................................................7-3

Neutral....................................................................................................................................7-3

1st Gear................................................................................................................................7-3

2nd Gear..............................................................................................................................7-3

3rd Gear................................................................................................................................7-3

4th Gear................................................................................................................................7-3

5th Gear................................................................................................................................7-3

6th Gear................................................................................................................................7-3

Shifter Linkage Adjustment..............................................................................7-5

7.3 Shifter Forks..................................................................7-6

Cleaning and Inspection......................................................................................7-6

7.4 Transmission Clutch Release

Cover......................................................................................................7-7

Removal/Disassembly............................................................................................7-7

Cleaning and Inspection......................................................................................7-8

Assembly/Installation................................................................................................7-8

7.5 Transmission Assembly............................7-9

Removal........................................................................................................................................7-9

Disassembly..........................................................................................................................7-11

Countershaft..................................................................................................................7-17

Cleaning and Inspection......................................................................................7-19

Replacing Side Door Bearings............................................................7-19

Assembly....................................................................................................................................7-20

Installation..................................................................................................................................7-22
 

7.6 Main Drive Gear And Bearing..........7-24

Removal........................................................................................................................................7-24

Cleaning and Inspection......................................................................................7-26

Needle Bearing Replacement..............................................................7-27

Installation..................................................................................................................................7-30

Installing Main Drive Gear........................................................................7-31

Installing Main Drive Gear Seal........................................................7-32

7.7 Transmission Case............................................7-34

Removal........................................................................................................................................7-34

General..................................................................................................................................7-34

Disassembly..........................................................................................................................7-34

Shifter Arm Assembly......................................................................................7-34

Cleaning and Inspection......................................................................................7-36

Assembly....................................................................................................................................7-37

Countershaft Needle Bearing Replacement..................7-37

Shifter Pawl Lever Assembly................................................................7-37

SECTION 8-ELECTRICAL
8.1 Specifications............................................................8-1

Torque Values (table)..............................................................................................8-1

8.2 Bulb Requirements............................................8-3

General..........................................................................................................................................8-3

Softail Bulb Chart (table)..............................................................................8-3

8.3 Electrical Panel........................................................8-4

General..........................................................................................................................................8-4

Removal........................................................................................................................................8-4

Installation..................................................................................................................................8-5

8.4 Electronic Control Module (ECM) 8-6

General..........................................................................................................................................8-6

Removal........................................................................................................................................8-6

Installation..................................................................................................................................8-7

8.5 Crank Position Sensor (CKP)..........8-8

General..........................................................................................................................................8-8

Removal........................................................................................................................................8-8

Installation..................................................................................................................................8-9

8.6 Spark Plug Cables..............................................8-10

General..........................................................................................................................................8-10

Removal........................................................................................................................................8-10

Inspection..................................................................................................................................8-11

Installation..................................................................................................................................8-11

8.7 Ignition Coil....................................................................8-12

Removal........................................................................................................................................8-12

Installation..................................................................................................................................8-12

8.8 Fuses........................................................................................8-13

General..........................................................................................................................................8-13

Removal........................................................................................................................................8-13

Installation..................................................................................................................................8-13

8.9 Relays......................................................................................8-14

General................................................;........................................8-14

Removal........................................................................................................................................8-14

Installation..................................................................................................................................8-14
8.10 Main Fuse......................................................................8-15

Removal......................................................................................................................................8-15

Installation................................................................................................................................8-15

8.11 Ignition/Light Switch..................................8-16

General..........................................................................................................................................8-16

Replacement........................................................................................................................8-16

Key Switch Functions and Positions (table)..................8-16

8.12 Alternator......................................................................8-17

Removal/Disassembly............................................................................................8-17

Cleaning/Inspection....................................................................................................8-17

Assembly/Installation................................................................................................8-17

8.13 Voltage Regulator............................................8-18

General..........................................................................................................................................8-18

8.14 Front Electrical Caddy............................8-20

General..........................................................................................................................................8-20

Disassembly..........................................................................................................................8-20

Assembly....................................................................................................................................8-22

8.15 Battery................................................................................8-24

Battery Testing..................................................................................................................8-24

General..................................................................................................................................8-24

Voltmeter Test............................................................................................................8-24

Voltmeter Test For Battery Charge Conditions (table) 8-24

Conductance Test................................................................................................8-24

Load Test..........................................................................................................................8-25

Battery Load Test (table)............................................................................8-25

Charging Battery............................................................................................................8-26

Safety Precautions..............................................................................................8-26

Using a Battery Charger..............................................................................8-26

Battery Charging Rates/Times (Approximate) (table) 8-26

8.16 Battery Cables......................................................8-28

Routing Procedure......................................................................................................8-28

8.17 Headlamp......................................................................8-30

General..........................................................................................................................................8-30

Removal/Installation..................................................................................................8-30

FXSTD, FXSTS and FLSTSC Models....................................8-30

FXST and FXSTB Models........................................................................8-31

FLSTC, FLSTF and FLSTN Models..........................................8-31

8.18 Tail Lamp: All But FXSTD/

FLSTSC/FLSTN....................................................................8-33

General..........................................................................................................................................8-33

Bulb Replacement........................................................................................................8-33

Base Replacement......................................................................................................8-33

Tail Lamp Wires (table)................................................................................8-34

8.19 Tail Lamp: FXSTD............................................8-35

Removal......................................................................................................................................8-35

Installation................................................................................................................................8-36

8.20 Tail Lamp: FLSTSC/FLSTN..............8-37

Bulb Replacement........................................................................................................8-37

Tail Lamp Replacement......................................................................................8-37
 

 

8.21 Auxiliary Lamps: FLSTC/FLSTN 8-39
Auxiliary Lamp Bulb....................................................................................................8-39

Removal................................................................................................................................8-39

Installation..........................................................................................................................8-39

FLSTC Models....................................................................................................................8-40

Auxiliary Lamp Bracket Removal....................................................8-40

Auxiliary Lamp Bracket Installation..............................................8-40

Auxiliary Lamp Housing Removal..................................................8-40

Auxiliary Lamp Housing Installation............................................8-40

FLSTN Models....................................................................................................................8-42

Auxiliary Lamp Bracket Removal....................................................8-42

Auxiliary Lamp Bracket Installation..............................................8-42

Auxiliary Lamp Housing Removal..................................................8-44

Auxiliary Lamp Housing Installation............................................8-44

Adjustment: FLSTC/FLSTN Models....................................................8-45

8.22 Front Fender Lamp: FLSTSC.... 8-46

Removal........................................................................................................................................8-46

Installation..................................................................................................................................8-46

8.23 Turn Signals/Running Lights.... 8-47

Bulb Replacement: All But FLSTC........................................................8-47

Bulb Replacement: FLSTC ............................................................................8-47

Lamp Replacement......................................................................................................8-47

Front Turn Signals: All But FLSTC, FLSTN, FLSTSC,

FXSTS......................................................................................................................................8-48

Front Turn Signals: FLSTSC, FXSTC......................................8-49

Rear Turn Signals: All But FXSTD, FLSTSC, FLSTN 8-50

Rear Turn Signals: FXSTD......................................................................8-50

Rear Turn Signals: FLSTSC..................................................................8-51

Rear Turn Signals: FLSTN........................................................................8-51

8.24 TSM/TSSM/HFSM..............................................8-52

General..........................................................................................................................................8-52

Removal........................................................................................................................................8-52

Installation..................................................................................................................................8-52

TSM/TSSM Configuration..................................................................................8-53

8.25 Fuel Gauge..................................................................8-54

General..........................................................................................................................................8-54

Removal........................................................................................................................................8-54

Installation..................................................................................................................................8-55

8.26 Instrument Console: FXSTD..........8-56

Removal........................................................................................................................................8-56

Installation..................................................................................................................................8-56

8.27 Speedometer: All But FXSTD ... 8-57

Removal........................................................................................................................................8-57

Installation..................................................................................................................................8-57

8.28 Speedometer: FXSTD................................8-58

Removal........................................................................................................................................8-58

Installation..................................................................................................................................8-58

8.29 Vehicle Speed Sensor: VSS............8-59

General..........................................................................................................................................8-59

Removal........................................................................................................................................8-59

Installation..................................................................................................................................8-59
8.30 Indicator Lamps: All But FXSTD 8-60

General..........................................................................................................................................8-60

Removal........................................................................................................................................8-60

Installation..................................................................................................................................8-60

Connector [21] Pins (table)......................................................................8-60

Indicator Lamp Assembly Wiring (table)..............................8-60

8.31 Indicator Lamps: FXSTD............ 8-61

General..........................................................................................................................................8-61

Removal........................................................................................................................................8-61

Installation..................................................................................................................................8-61

8.32 Neutral Switch............................ 8-62

General..........................................................................................................................................8-62

Removal........................................................................................................................................8-62

Installation..................................................................................................................................8-62

8.33 Oil Pressure Switch.................... 8-63

General..........................................................................................................................................8-63

Removal........................................................................................................................................8-63

Installation..................................................................................................................................8-63

8.34 Rear Stop Light Switch.............. 8-64

General..........................................................................................................................................8-64

Removal........................................................................................................................................8-64

Installation..................................................................................................................................8-64

8.35 Horn............................................. 8-65

Inspection..................................................................................................................................8-65

Replacement..........................................................................................................................8-65

8.36 Active Exhaust Module.............. 8-66

General..........................................................................................................................................8-66

Removal........................................................................................................................................8-66

Repair..............................................................................................................................................8-67

Installation..................................................................................................................................8-67

8.37 Main Wiring Harness.................. 8-68

Removal........................................................................................................................................8-68

Installation..................................................................................................................................8-70

8.38 Handlebar Switch Assemblies.. 8-72

General..........................................................................................................................................8-72

Repair Procedures........................................................................................................8-72

8.39 Right Handlebar Switch............. 8-73

Removal........................................................................................................................................8-73

Installation..................................................................................................................................8-73

Disassembly..........................................................................................................................8-75

Switch Repair/Replacement..........................................................................8-76

Upper Housing Repair....................................................................................8-76

Lower Housing Repair....................................................................................8-77

Assembly....................................................................................................................................8-78

8.40 Left Handlebar Switch................ 8-79

Removal........................................................................................................................................8-79

Installation..................................................................................................................................8-79

Disassembly..........................................................................................................................8-80

Switch Repair/Replacement..........................................................................8-80

Upper Housing Repair....................................................................................8-80

Lower Housing Repair....................................................................................8-82

Assembly....................................................................................................................................8-83
 

 APPENDIX A-TOOLS
A.1 Tools..........................................................................................A-1

APPENDIX B-WIRING
B.1 Amp 1-Place Connector............................B-1

Pin and Socket Housings....................................................................................B-1

To Separate Housings....................................................................................B-1

To Mate Housings..................................................................................................B-1

Wire Terminals....................................................................................................................B-1

Remove Socket Terminals........................................................................B-1

Install Socket Terminal..................................................................................B-2

Remove Pin Terminals..................................................................................B-2

Install Pin Terminals..........................................................................................B-2

B.2 Amp Multilock............................................................B-3

Pin and Socket Housings....................................................................................B-3

Separate Housings..............................................................................................B-3

Mate Housings............................................................................................................B-3

Wire Terminals....................................................................................................................B-4

Remove Terminals from Housing..................................................B-4

Insert Terminals into Housings..........................................................B-5

Terminal Crimps..............................................................................................................B-6

Prepare Wire Leads............................................................................................B-6

Crimp Terminals to Leads..........................................................................B-6

Inspect Crimp........................................................................................................................B-7

B.3 Delphi Connectors............................................B-8

Pin and Socket Housings....................................................................................B-8

Tо Separate Housings....................................................................................B-8

To Mate Housings..................................................................................................B-8

Wire Terminals....................................................................................................................B-8

Remove Socket Terminals........................................................................B-8

Install Socket Terminals................................................................................B-9

Housing..........................................................................................................................................B-10

To Separate Housings....................................................................................B-10

To Mate Housings..................................................................................................B-10

Wire T erminals....................................................................................................................B-10

Remove T erminal..................................................................................................B-10

Installation..........................................................................................................................B-10

B.5 Deutsch........................................ B-11

Pin and Socket Housings....................................................................................B-11

Separate Housings..............................................................................................B-11

Mate Housings............................................................................................................B-11

Wire Terminals....................................................................................................................B-12

Remove Socket Terminals.................................... B-12

Install Socket Terminals................................................................................B-12

Remove Pin Terminals..................................................................................B-13

install Pin Terminals............................................................................................B-14

Terminal Crimps..............................................................................................................B-14

B.6 Standard Deutsch Terminal Crimps................................................. B-15

Terminal Crimps..............................................................................................................B-15

Prepare Wire Lead................................................................................................B-15

Crimp Terminal to Lead........................................ B-15

Inspect Crimp................................................................................................................B-15


B.7 Deutsch Mini Terminal Crimps.. B-16

Terminal Crimps..............................................................................................................B-16

Prepare Wire Lead..............................................................................................B-16

Crimp a Mini Terminal to a Wire Lead....................................B-16

Inspect Crimp..............................................................................................................B-16

B.8 Deutsch Solid Barrel Terminal Crimps................................................................................................B-17

Wire Terminals..................................................................................................................B-17

Prepare Wire Lead..............................................................................................B-17

Adjust Crimper Tool............................................................................................B-17

Crimp Barrel Contact to Wire Lead............................................B-18

Inspect Crimp..............................................................................................................B-18

B.9 Fuse Blocks..................................................................B-19

Fuse Wire Leads............................................................................................................B-19

Remove Socket Terminals......................................................................B-19

Install Socket Terminals..............................................................................B-19

Terminal Crimps..............................................................................................................B-20

B.10 150 Metri-Pack......................................................B-21

Pin and Socket Housings..................................................................................B-21

Wire Terminals..................................................................................................................B-21

Remove Terminals..............................................................................................B-21

Insert Terminals........................................................................................................B-21

Terminal Crimps..............................................................................................................B-21

B.11 280 Metri-Pack......................................................B-23

Pin and Socket Housings..................................................................................B-23

To Separate Housings....................................................................................B-23

To Mate Housings................................................................................................B-23

Wire T erminals................................................................................................................B-23

Remove Socket Terminals......................................................................B-23

Install Socket Terminals..............................................................................B-23

Terminal Crimps..............................................................................................................B-24

B.12 480 Metri-Pack......................................................B-25

Pin and Socket Housings..................................................................................B-25

To Separate Housings....................................................................................B-25

To Mate Housings................................................................................................B-25

Wire Terminals..................................................................................................................B-25

Remove Socket Terminal..........................................................................B-25

Install Socket Terminal..................................................................................B-26

B.13 630 Metri-Pack......................................................B-27

Pin and Socket Housings..................................................................................B-27

Separate Housings..............................................................................................B-27

Mate Housings..........................................................................................................B-27

Wire Terminals..................................................................................................................B-27

Remove Socket Terminals......................................................................B-27

Install Socket Terminals..............................................................................B-27

B.14 800 Metri-Pack......................................................B-28

Fuse and Socket Housing................................................................................B-28

Remove the Maxi-Fuse................................................................................B-28

Install Maxi-Fuse....................................................................................................B-28

Wire Terminals..................................................................................................................B-28

Remove Socket Terminals.............................................................................B-28

Install Socket Terminals.............................................................................B-29

Terminal Crimps..............................................................................................................B-29
 

 

 B.15 Metri-Pack Terminal Crimps .... B-30

Match Terminal to Crimper................................................................................B-30

Terminal Crimps................................................................................................................B-31

Prepare Wire Lead................................................................................................B-31

Crimp Wire Core......................................................................................................B-31

Crimp Insulation/Seal........................................................................................B-31

Inspect Crimp........................................................................................................................B-31

B.16 Packard 100W........................................................B-32

Socket Housing..................................................................................................................B-32

Separate Socket Housing from ECM........................................B-32

Mate Socket Housing to ECM..............................................................B-32

Wire Terminals....................................................................................................................B-32

Remove Socket Terminals........................................................................B-32

Install Socket Terminals................................................................................B-32

B.17 Molex....................................................................................B-34

Pin and Socket Housings....................................................................................B-34

Separate the Housings..................................................................................B-34

Mate the Housings................................................................................................B-34

Wire T erminals....................................................................................................................B-34

Remove Terminals................................................................................................B-34

Install Terminal............................................................................................................B-35

B.18 Packard Micro 64 ..........................................B-36

Pin and Socket Housings....................................................................................B-36

Separate the Housings..................................................................................B-36

Mate the Housings................................................................................................B-36

Wire Terminals....................................................................................................................B-36

Remove Terminals................................................................................................B-36

Install Terminals........................................................................................................B-37

Terminal Crimps................................................................................................................B-38

Prepare Wire Lead................................................................................................B-38

Crimp Terminal............................................................................................................B-38

Inspect Crimp................................................................................................................B-38

B.19 Sealed Splice..........................................................B-39

Prepare Wire Leads....................................................................................................B-39

Splicing Wire Leads....................................................................................................B-40

Inspect Seal............................................................................................................................B-40

B.20 Connector Locations................................B-41

B.21 Index to Wiring Diagrams..................B-43

Wire Color Codes............................................................................................................B-43

Wiring Diagram Symbols......................................................................................B-43

APPENDIX C-METRIC CONVERSIONS
C.1 Metric Conversions..........................................C-1

C.2 Fluid Conversions..............................................C-2

United States System................................................................................................C-2

Metric System......................................................................................................................C-2

British Imperial System..........................................................................................C-2

APPENDIX D-GLOSSARY
D.1 Glossary....................................... D-l

INDEX

 

 

MAINTENANCE
SUBJECT PAGE NO.

1.1 General ............................................................................................................1-1

1.2 Fuel and Oil......................................................................................................1-5

1.3 Maintenance Schedule ....................................................................................1-6

1.4 Engine Oil and Filter ........................................................................................1-11

1.5 Battery Maintenance........................................................................................1-13

1.6 Brakes..............................................................................................................1-16

1.7 Bleeding Brakes................................................................................................1-18

1.8 Brake Pads and Discs......................................................................................1-19

1.9 Tires and Wheels..............................................................................................1-23

1.10 Primary Chain ................................................................................................1-25

1.11 Primary Chaincase Lubricant..........................................................................1-26

1.12 Clutch..............................................................................................................1-28

1.13 Transmission Lubricant..................................................................................1-30

1.14 Rear Belt Deflection........................................................................................1-31

1.15 Rear Belt and Sprockets ................................................................................1-33

1.16 Suspension Adjustments................................................................................1-35

1.17 Steering Head Bearings: All But FLSTSC......................................................1-36

1.18 Steering Head Bearings: FLSTSC..................................................................1-37

1.19 Rocker Bearings: FLSTSC ............................................................................1-39

1.20 Front Fork Oil..................................................................................................1-41

1.21 Spark Plugs....................................................................................................1-43

1.22 Air Cleaner Filter............................................................................................1-44

1.23 Cable and Chassis Lubrication ......................................................................1-46

1.24 Throttle Cables ..............................................................................................1-47

1.25 Engine Mounts................................................................................................1-49

1.26 Headlamp Alignment......................................................................................1-50

1.27 Critical Fasteners............................................................................................1-52

1.28 Storage ..........................................................................................................1-53

1.29 Troubleshooting..............................................................................................1-55

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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